Deep bed filter with inclusion containment barrier

Abstract

A deep bed filter for molten metal includes a housing with an inlet, an outlet, a filtering region between the inlet and the outlet, and a containment region between the filtering region and the outlet. The containment region may remove inclusions from the flow of molten metal after the molten metal passes through the filtering region. A method of filtering molten metal includes introducing the molten metal into the deep bed filter such that (i) the molten metal flows into a filtering region of a deep bed filter to generate intermediately filtered molten metal and (ii) the intermediately filtered molten metal flows through the containment region to remove inclusions from the intermediately filtered molten metal and to generate filtered molten metal.

Description

DEEP BED FILTER WITH INCLUSION CONTAINMENT BARRIERREFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of and priority to U.S. Provisional Patent Application No. 63 / 650,503, filed on May 22, 2024, and entitled DEEP BED FILTER WITH INCLUSION CONTAINMENT BARRIER, the content of which is hereby incorporated by reference in its entirety.FIELD OF THE INVENTION

[0002] This application relates to systems and methods for the filtration of liquid or molten metal.BACKGROUND

[0003] Metals such as aluminum and aluminum alloys often must meet quality requirements for various applications, and the presence of inclusions (such as but not limited to oxides) may lead to various quality issues, particularly for metal products with reduced thicknesses. Accordingly, it is common to filter liquid or molten metal prior to formation of a cast product in an attempt to remove such solids or inclusions and thereby produce a higher quality metal product. Various filtration systems have been utilized, and a common filtration system is a deep bed filter system. Such systems include a bed of refractory materials (commonly in the form of alumina balls) packed and layered in an insulated housing, and molten metal is passed through the bed, often in a top-to-bottom direction. As the metal moves through the bed, progressively fewer and fewer inclusions are present in the metal, and the inclusions deposit and accumulate on the surface of the refractory materials. While traditional deep bed filters are relatively efficient, any instability or disturbance of the bed and / or the refractory materials contained there may cause detachment of the inclusions, thereby re-releasing the inclusions into the metal and decreasing filter efficiency.SUMMARY

[0004] Embodiments covered by this patent are defined by the claims below, not this summary. This summary is a high-level overview of various embodiments and introduces someof the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this patent, any or all drawings, and each claim.

[0005] According to certain embodiments, a deep bed filter for molten metal includes a housing with a molten metal inlet, a molten metal outlet, a filtering region between the molten metal inlet and the molten metal outlet, and a containment region between the filtering region and the molten metal outlet. The filtering region may remove inclusions from a flow of molten metal to generate intermediately filtered molten metal. The containment region may include at least one containment barrier extending into the flow of intermediately filtered molten metal that may remove inclusions from the flow of intermediately filtered molten metal to generate filtered molten metal.

[0006] According to certain embodiments, a containment structure for a deep bed filter includes an upper portion, a lower portion, and a flow region between the upper portion and the lower portion. The filtering structure may receive a flow of molten metal from a filtering region of the deep bed filter through the upper portion and into the flow region. The lower portion includes at least one containment barrier for removing inclusions from the flow of molten metal in the flow region.

[0007] According to certain embodiments, a method of filtering molten metal includes introducing molten metal into a deep bed filter such that the molten metal flows into a filtering region of a deep bed filter to generate intermediately filtered molten metal and such that the intermediately filtered molten metal flows through a containment region comprising at least one containment barrier to remove inclusions from the intermediately filtered molten metal and to generate filtered molten metal.

[0008] Various implementations described herein can include additional systems, methods, features, and advantages, which cannot necessarily be expressly disclosed herein but will be apparent to one of ordinary skill in the art upon examination of the following detailed description and accompanying drawings. It is intended that all such systems, methods, features, and advantages be included within the present disclosure and protected by the accompanying claims.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The specification makes reference to the following appended figures, in which use of like reference numerals in different figures is intended to illustrate like or analogous components.

[0010] FIG. 1 illustrates a deep bed filter with at least one containment barrier according to embodiments.

[0011] FIG. 2 is a perspective view of a housing of the deep bed filter of FIG. 1.

[0012] FIG. 3 is a sectional view of the housing of the deep bed filter of FIG. 1.

[0013] FIG. 4 is a perspective view of a portion of the deep bed filter of FIG. 1.

[0014] FIG. 5 is a perspective view of a containment structure for the deep bed filter of FIG. 1.

[0015] FIG. 6 is a perspective sectional view of the containment structure of FIG. 5.

[0016] FIG. 7 is a sectional view of the containment structure of FIG. 5.

[0017] FIG. 8 illustrates inclusions being trapped by the containment structure of FIG. 5 during molten metal flow through the deep bed filter.

[0018] FIG. 9 is a perspective sectional view of another deep bed filter with the at least one containment barrier according to embodiments.

[0019] FIG. 10 illustrates an arrangement of containment barriers for a deep bed filter according to embodiments.

[0020] FIG. 11 illustrates another arrangement of containment barriers for a deep bed filter according to embodiments.DETAILED DESCRIPTION

[0021] Described herein are systems and methods for improved filtration of molten or liquid metal, such as but not limited to aluminum or aluminum alloys, using a deep bed filter. In certain embodiments, the systems and methods described herein utilize one or more containment barriers downstream from a filtering region of the deep bed filter. Compared to traditional approaches, the systems and methods disclosed herein may provide filtration with improved efficiency as inclusions that were not filtered by a filtration region (e.g., by not being captured by refractory materials such as but not limited to alumina balls and / or by beingdislodged) may be further captured and removed from the metal flow. Advantageously, the systems and methods described herein may provide improved filtration and capture of inclusions without requiring additional space by utilizing space of the deep bed filter traditionally without filter functionality.

[0022] In certain embodiments, the improved filtration may be realized using one or more containment barriers, which may be integral or monolithic with the housing of the deep bed filter and / or may be removable from the housing of the deep bed filter. In embodiments where a plurality of containment barriers are utilized, a characteristic of one containment barrier may be different from a characteristic of another containment barrier, although they need not be in other examples. Characteristics of containment barriers that may be controlled to further control filtration may include, but are not limited to, an orientation of the containment barrier relative to a flow of metal, a shape or profile of a surface facing in an upstream direction relative to the flow of metal, and / or a shape or profile of a surface facing in a downstream direction relative to the flow of metal.

[0023] By retaining more inclusions and other particles using the systems and methods described herein, the useful life of the deep bed filter may be increased compared to traditional approaches and / or the filtering efficiency of the deep bed filter may be increased compared to traditional approaches. Various other benefits and advantages may be realized with the systems and methods described herein, and the aforementioned benefits and advantages should not be considered limiting.

[0024] FIGS. 1-8 illustrate an example of a deep bed filter 100 for filtering molten metal according to embodiments. The molten metal may be various metals as desired, including but not limited to aluminum, aluminum alloys, steel, or other metals as desired. In some examples, the molten metal may be an aluminum or an aluminum alloy in the Ixxx series, 2xxx series, 3xxx series, 4xxx series, 5xxx series, 6xxx series, 7xxx series, 8xxx series and / or any other aluminum or aluminum alloy as desired.

[0025] The deep bed filter 100 generally includes a housing 102, which may include a refractory material or another material (e.g., metal) lined by a refractory material capable of withstanding exposure to the molten metal. The housing 102 defines a cavity 104 with a floor 116, and the housing 102 includes a metal inlet 106 and a metal outlet 108 through which metal enters or exits the cavity 104. The particular location of the metal inlet 106 and the metal outlet108 on the housing 102 should not be considered limiting. While not illustrated, in certain embodiments, a cover may be included to cover and enclose the cavity 104.

[0026] A partition wall 110 may sub-divide the cavity 104 into a first compartment 112 and a second compartment 114. In some embodiments, a volume of the first compartment 112 may be greater than a volume of the second compartment 114, although it need not. In other embodiments, the volume of the second compartment 114 may be substantially the same as and / or greater than the volume of the first compartment 112. The shape of the second compartment 114 as defined by the partition wall 110 should not be considered limiting, and in other embodiments, the partition wall 110 may form the second compartment 114 with various shapes or profiles as desired. As best illustrated in FIG. 3, the partition wall 110 may terminate with an end 126 at a location above the floor 116 of the cavity 104 such that a gap 118 is defined between the partition wall 110 and the floor 116. As discussed in detail below, metal may flow between the first compartment 112 and the second compartment 114 via the gap 118. A general flow path of metal through the deep bed filter is represented by arrow 101 in FIG. 1.

[0027] Referring to FIG. 1, the first compartment 112 includes a filtering region 120 and a containment region 130. The filtering region 120 may include refractory materials as filter media for filtering metal received in the cavity 104 to be intermediately filtered molten metal. The containment region 130 may include one or more containment barriers 132 for further removing or filtering inclusions and other particles that were not removed by the filtering region 120 and for filtering the intermediately filtered molten metal to be filtered molten metal. As used herein, “intermediately filtered molten metal” and “filtered molten metal” refer to relative levels of filtration. The filtering efficiency of the filtering region 120 may be similar to the filtering efficiency of traditional deep bed filters and thus the number of inclusions in the intermediately filtered molten metal may be similar to the number of inclusions in metal traditionally output by deep bed filters.

[0028] The filtering region 120 includes one or more beds or layers 122 of filter media, which may be various types and forms of refractory material as desired. Non-limiting examples of the filter media may be alumina balls, tablets, rings, etc. which may allow for contacting surfaces with voids therebetween. FIG. 1 illustrates the filtering region 120 with three layers 122A-C of filter media; however, in other embodiments, the filtering region 120 may include any number of layers 122 as desired, including a single layer 122, two layers 122, three layers 122, and / or more than three layers 122. In embodiments with a plurality of layers 122 of filter media,each layer 122 may have generally a similar size range, and the layers 122 may be arranged such that the filter media is progressively finer in size towards the floor 116 and / or along the direction of flow of metal through the housing 102. In this regard, while metal flow path 101 is represented as vertically and in a downward direction through the filtering region 120, it need not be vertical and / or downward in other embodiments. In FIG. 1, layer 122A may be coarse filter media, layer 122B may be medium filter media, and layer 122C may be fine filter media. Moreover, while each layer 122A-C is illustrated as having a similar depth or thickness in FIG. 1, they need not be in other embodiments.

[0029] The layers 122 of filter media of the filtering region 120 may be supported on one or more grates or grids 124 that include one or more openings or apertures 128. In various embodiments, the one or more grids 124 may be aligned with and / or in contact with the end 126 of the partition wall 110 such that metal must pass through the grids 124 before passing to the second compartment 114 and the metal outlet 108. Metal filtered by the filtering region 120 and initially passing through the grids 124 may be the intermediately filtered molten metal.

[0030] The containment region 130 is downstream from the filtering region 120 and may be at least between the grids 124 and the second compartment 114. While traditionally this region was without filter functionality, the containment region 130 of the deep bed filter 100, as best illustrated in FIGS. 1 and 5-8, includes one or more containment barriers 132 for trapping and filtering inclusions and / or other particles that were not filtered from the molten metal by the filtering region 120.

[0031] Any number of containment barriers 132 may be utilized within the containment region 130, and the number of containment barriers 132 should not be considered limiting. In various embodiments, the one or more containment barriers 132 are provided within the containment region 130 proximate to the floor 116 and such that the containment barriers 132 extend at least partially into the flow path 101 of metal in the containment region 130.

[0032] In some embodiments, and as illustrated in FIGS. 5-8, the one or more containment barriers 132 may be removable or separable from the housing 102. In such embodiments, the containment barriers 132 optionally may be provided as a portion of a containment structure 138 that may be selectively provided within or removed from the cavity 104 as desired. In such embodiments, any number of containment structures 138 may be provided within the housing as desired.

[0033] In various embodiments, the containment structure 138 includes an upper portion 140 and a lower portion 142. The upper portion 140 may include the grids 124 such that the upper portion 140 receives the intermediately filtered molten metal from the filtering region 120. The lower portion 142 may include the containment barriers 132, and a flow region 146 may be defined between the upper portion 140 and the lower portion 142. One or more connecting portions 144 optionally connects the upper portion 140 with the lower portion 142. In various embodiments, a height of the flow region 146 (e.g., a distance from the upper portion 140 to the lower portion 142) may be controlled by controlling one or more of a height of the grids 124, a height of the containment barriers 132, and / or a height of the connecting portions 144. While the containment structures 138 are illustrated as rectangular in FIGS. 5-8, in other embodiments, the containment structures 138 may have other shapes or profiles as desired. As a non-limiting example, the containment structures 138 may be triangular, hexagonal, and / or other shapes or profiles as desired. Moreover, a shape of the upper portion 140 need not be the same as a shape of the lower portion.

[0034] In other embodiments, and as illustrated in FIG. 9, the containment barriers 132 may be monolithically or integrally formed with the housing 102, such as but not limited to the floor 116 of the housing 102.

[0035] Each containment barrier 132 may include a first surface 134 for facing in a generally upstream direction relative to the flow path 101 and a second surface 136 facing in a generally downstream direction relative to the flow path 101. In certain embodiments, a characteristic of the first surface 134 may be different from a characteristic of the second surface 136, although it need not be in other embodiments. Non-limiting examples of characteristics that may be different between the first surface 134 and the second surface 136 include a shape of the surface, a profile of the surface, a length of the surface, and / or an angle relative to the floor 116. In FIGS. 5-8, the first surface 134 is generally planar and extends at an oblique angle relative to the floor 116 while the second surface 136 has a non-linear curvature and / or is arcuate-shaped. In other embodiments, first surfaces 134 and / or second surfaces 136 with other characteristics may be utilized as desired. In embodiments with a plurality of containment barriers 132, the containment barriers 132 may have uniform or non-uniform first surfaces 134 and / or second surfaces 136 as desired.

[0036] The containment barriers 132 may be provided at various orientations relative to the flow path 101. In some embodiments, and as illustrated in FIGS. 8 and 10, the containment barriers 132 may extend in a direction substantially perpendicular to the flow path 101. In otherembodiments, and as illustrated in FIG. 11 for example, the containment barriers 132 may extend at various other angles relative to the flow path 101. Moreover, in embodiments where a plurality of containment barriers are utilized, the containment barriers 132 may have a same orientation relative to the flow path 101 (see, e.g., FIG. 10) or at least one containment barrier 132 may have an orientation that is different compared to another containment barrier 132 (see, e.g., FIG. 11). In some embodiments, and as illustrated in FIGS. 5 and 6, an orientation of the containment barriers 132 may be the same as an orientation of the apertures 128, although they need not be in other embodiments.

[0037] Regardless of the particular orientation relative to the flow path 101, as illustrated in FIG. 8, the containment barriers 132 may filter or trap inclusion 103 from the metal flowing along the flow path 101, thereby improving the filtering efficiency and producing the filtered molten metal.

[0038] FIG. 9 illustrates an example of another deep bed filter 900 that is substantially similar to the deep bed filter 100 except that the containment barriers 132 are integrally formed with the housing 102. In FIG. 9, the containment barriers 132 extend from the floor 116 of the housing 102 and extend substantially perpendicular to a direction of flow. While not illustrated in FIG. 9, similar to the deep bed filter 100, the deep bed filter 900 may include the grids 124 for separating the first compartment 112 into the filtering region 120 and the containment region 130.

[0039] Referring back to FIG. 1, a method of filtering molten metal such as but not limited to aluminum or aluminum alloys includes introducing the metal into the cavity 104 via the metal inlet 106. Introducing the metal into the cavity 104 via the metal inlet 106 introduces the metal into the filtering region 120, and the metal passes through the one or more layers 122 of filter media such that inclusions and other particles are progressively filtered from the metal. The molten metal may exit the filtering region 120 as intermediately filtered molten metal and be directed through the grids 124 and into the containment region 130. In certain embodiments, the molten metal may be directed into the flow region 146 of a containment structure 138 and may flow through the containment region 130, through the gap 118, into the second compartment 114, and to the metal outlet 108. In various embodiments, as the intermediately filtered molten metal flows along the flow path 101 through the containment region 130, the one or more containment barriers 132 may filter and remove inclusions and other particles from the intermediately filtered molten metal that were not filtered by the filtering region, thereby producing a filtered molten metal that is provided to the metal outlet 108. In certainembodiments, a filtering efficiency of the deep bed filter 100 may be controlled by controlling one or more of a refractory material of the layers 122 of the filtering region 120, a number of layers 122 of the filtering region 120, a number of containment barriers 132, an orientation of the containment barriers 132 relative to the flow path 101, a profile of the containment barriers 132, and / or other aspects of the filtering region 120 and / or the containment region 130 as desired.

[0040] A collection of exemplary embodiments is provided below, including at least some explicitly enumerated as an “Illustration” providing additional description of a variety of example embodiments in accordance with the concepts described herein. These illustrations are not meant to be mutually exclusive, exhaustive, or restrictive; and the disclosure not limited to these example illustrations but rather encompasses all possible modifications and variations within the scope of the issued claims and their equivalents.

[0041] Illustration 1. A deep bed filter for molten metal, the deep bed filter comprising: a housing comprising a molten metal inlet and a molten metal outlet; a filtering region between the molten metal inlet and the molten metal outlet configured to remove inclusions from a flow of molten metal to generate intermediately filtered molten metal; and a containment region between the filtering region and the molten metal outlet, the containment region comprising at least one containment barrier extending into the flow of intermediately filtered molten metal and configured to remove inclusions from the flow of intermediately filtered molten metal to generate filtered molten metal.

[0042] Illustration 2. The deep bed filter of any preceding or subsequent illustration or combination of illustrations, wherein the containment region comprises a containment structure an upper portion and a lower portion, wherein the upper portion is configured to receive the molten metal from the filtering region, wherein the at least one containment barrier is on the lower portion, and wherein a flow region is defined between the upper portion and the lower portion.

[0043] Illustration 3. The deep bed filter of any preceding or subsequent illustration or combination of illustrations, wherein the at least one containment barrier extends in a direction substantially perpendicular to a direction of the flow of molten metal.

[0044] Illustration 4. The deep bed filter of any preceding or subsequent illustration or combination of illustrations, wherein the at least one containment barrier comprises a first surface facing in an upstream direction relative to the flow of molten metal and a second surfacefacing in a downstream direction relative to the flow of molten metal, and wherein a profile of the first surface is different from a profile of the second surface.

[0045] Illustration 5. The deep bed filter of any preceding or subsequent illustration or combination of illustrations, wherein the first surface is planar and the second surface comprises a non-linear curvature.

[0046] Illustration 6. The deep bed filter of any preceding or subsequent illustration or combination of illustrations, wherein the first surface extends at an oblique angle relative to a lower surface of the housing and in in the upstream direction.

[0047] Illustration 7. The deep bed filter of any preceding or subsequent illustration or combination of illustrations, wherein the at least one containment barrier is integrally formed with the housing.

[0048] Illustration 8. The deep bed filter of any preceding or subsequent illustration or combination of illustrations, wherein the at least one containment barrier comprises a plurality of containment barriers, wherein at least one containment barrier of the plurality of containment barriers has a first orientation relative to the flow of molten metal and at least one containment barrier of the plurality of containment barriers has a second orientation relative to the flow of molten metal different from the first orientation.

[0049] Illustration 9. A containment structure for a deep bed filter, the containment structure comprising: an upper portion; a lower portion; and a flow region between the upper portion and the lower portion, wherein the containment structure is configured to receive a flow of molten metal from a filtering region of the deep bed filter through the upper portion and into the flow region, and wherein the lower portion comprises at least one containment barrier configured to remove inclusions from the flow of molten metal in the flow region.

[0050] Illustration 10. The containment structure of any preceding or subsequent illustration or combination of illustrations, wherein the at least one containment barrier comprises a first surface and a second surface, and wherein a profile of the first surface is different from a profile of the second surface.

[0051] Illustration 11. The containment structure of any preceding or subsequent illustration or combination of illustrations, wherein the first surface is planar and the second surface comprises a non-linear curvature.

[0052] Illustration 12. The containment structure of any preceding or subsequent illustration or combination of illustrations, wherein the first surface faces in an upstream direction relative to the flow of molten metal and the second surface faces in a downstream direction relative to the flow of molten metal.

[0053] Illustration 13. The containment structure of any preceding or subsequent illustration or combination of illustrations, wherein the at least one containment barrier extends substantially perpendicular to the flow of molten metal.

[0054] Illustration 14. A method of filtering molten metal, the method comprising introducing molten metal into a deep bed filter such that: the molten metal flows into a filtering region of the deep bed filter to generate intermediately filtered molten metal; and the intermediately filtered molten metal flows through into a containment region comprising at least one containment barrier to remove inclusions from the intermediately filtered molten metal and to generate filtered molten metal before passing to an outlet of the deep bed filter.

[0055] Illustration 15. The method of any preceding or subsequent illustration or combination of illustrations, further comprising orienting the at least one containment barrier to extend substantially perpendicular to a direction of molten metal flow through the containment region.

[0056] Illustration 16. The method of any preceding or subsequent illustration or combination of illustrations, further comprising positioning the containment region below the filtering region.

[0057] Illustration 17. The method of any preceding or subsequent illustration or combination of illustrations, wherein the containment region comprises a containment structure comprising an upper portion and a lower portion, wherein the upper portion forms a lower surface of the filtering region, and wherein the lower portion comprises the at least one containment barrier, and wherein the method comprises introducing the molten metal such that the molten metal flows through the upper portion.

[0058] Illustration 18. The method of any preceding or subsequent illustration or combination of illustrations, wherein the at least one containment barrier comprises a plurality of containment barriers, and wherein the method comprises providing the plurality of containment barriers in at least two orientations relative to a direction of molten metal flow.

[0059] Illustration 19. The method of any preceding or subsequent illustration or combination of illustrations, further comprising orienting the at least one containment barrier such that afirst surface of the at least one containment barrier faces into a flow of the molten metal and a second surface of the at least one containment barrier faces away from the flow of the molten metal, and wherein a profile of the first surface is different from a profile of the second surface.

[0060] Illustration 20. The method of any preceding or subsequent illustration or combination of illustrations, wherein the first surface is planar and extends at an oblique angle relative to a bottom surface of the deep bed filter and wherein the second surface comprises a non-linear curvature.

[0061] As used herein, the terms “invention,” “the invention,” “this invention,” and “the present invention” are intended to refer broadly to all of the subject matter of this patent application and the claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below.

[0062] In this description, reference is made to alloys identified by AA numbers and other related designations, such as “series” or “5xxx.” For an understanding of the number designation system most commonly used in naming and identifying aluminum and its alloys, see “International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys” or “Registration Record of Aluminum Association Alloy Designations and Chemical Compositions Limits for Aluminum Alloys in the Form of Castings and Ingot,” both published by The Aluminum Association.

[0063] As used herein, the meaning of “a,” “an,” and “the” includes singular and plural references unless the context clearly dictates otherwise.

[0064] The subject matter of embodiments of the present disclosure is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described. Directional references such as “up,” “down,” “top,” “bottom,” “left,” “right,” “vertical,” “horizontal,” “lateral,” “longitudinal,” “front,” and “back,” among others, are intended to refer to the orientation as illustrated and described in the figure (or figures) to which the components and directions are referencing.

[0065] The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate embodiments of the invention, and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

[0066] The above-described aspects are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the present disclosure. Many variations and modifications can be made to the above-described embodiment(s) without departing substantially from the spirit and principles of the present disclosure. All such modifications and variations are intended to be included herein within the scope of the present disclosure, and all possible claims to individual aspects or combinations of elements or steps are intended to be supported by the present disclosure. Moreover, although specific terms are employed herein, as well as in the claims that follow, they are used only in a generic and descriptive sense, and not for the purposes of limiting the described embodiments, nor the claims that follow.

Claims

CLAIMSThat which is claimed:

1. A deep bed filter for molten metal, the deep bed filter comprising: a housing comprising a molten metal inlet and a molten metal outlet; a filtering region between the molten metal inlet and the molten metal outlet configured to remove inclusions from a flow of molten metal to generate intermediately filtered molten metal; and a containment region between the filtering region and the molten metal outlet, the containment region comprising at least one containment barrier extending into the flow of the intermediately filtered molten metal and configured to remove inclusions from the intermediately filtered molten metal to generate filtered molten metal.

2. The deep bed filter of claim 1, wherein the containment region comprises a containment structure comprising an upper portion and a lower portion, wherein the upper portion is configured to receive the molten metal from the filtering region, wherein the at least one containment barrier is on the lower portion, and wherein a flow region is defined between the upper portion and the lower portion.

3. The deep bed filter of claim 1, wherein the at least one containment barrier extends in a direction substantially perpendicular to a direction of the flow of molten metal.

4. The deep bed filter of claim 1, wherein the at least one containment barrier comprises a first surface facing in an upstream direction relative to the flow of molten metal and a second surface facing in a downstream direction relative to the flow of molten metal, and wherein a profile of the first surface is different from a profile of the second surface.

5. The deep bed filter of claim 4, wherein the first surface is planar and the second surface comprises a non-linear curvature.

6. The deep bed filter of claim 4, wherein the first surface extends at an oblique angle relative to a lower surface of the housing and in the upstream direction.

7. The deep bed filter of claim 1, wherein the at least one containment barrier is integrally formed with the housing.

8. The deep bed filter of claim 1, wherein the at least one containment barrier comprises a plurality of containment barriers, wherein at least one containment barrier of the plurality of containment barriers has a first orientation relative to the flow of molten metal and at least one containment barrier of the plurality of containment barriers has a second orientation relative to the flow of molten metal different from the first orientation.

9. A containment structure for a deep bed filter, the containment structure comprising: an upper portion; a lower portion; and a flow region between the upper portion and the lower portion, wherein the containment structure is configured to receive a flow of molten metal from a filtering region of the deep bed filter through the upper portion and into the flow region, and wherein the lower portion comprises at least one containment barrier configured to remove inclusions from the flow of molten metal in the flow region.

10. The containment structure of claim 9, wherein the at least one containment barrier comprises a first surface and a second surface, and wherein a profile of the first surface is different from a profile of the second surface.

11. The containment structure of claim 10, wherein the first surface is planar and the second surface comprises a non-linear curvature.

12. The containment structure of claim 11, wherein the first surface faces in an upstream direction relative to the flow of molten metal and the second surface faces in a downstream direction relative to the flow of molten metal.

13. The containment structure of claim 9, wherein the at least one containment barrier extends substantially perpendicular to the flow of molten metal.

14. A method of filtering molten metal, the method comprising introducing molten metal into a deep bed filter such that: the molten metal flows into a filtering region of the deep bed filter to generate intermediately filtered molten metal; and the intermediately filtered molten metal flows through a containment region comprising at least one containment barrier to remove inclusions from the intermediately filtered molten metal and to generate filtered molten metal before passing to an outlet of the deep bed filter.

15. The method of claim 14, further comprising orienting the at least one containment barrier to extend substantially perpendicular to a direction of molten metal flow through the containment region.

16. The method of claim 14, further comprising positioning the containment region below the filtering region.

17. The method of claim 14, wherein the containment region comprises a containment structure comprising an upper portion and a lower portion, wherein the upper portion forms a lower surface of the filtering region, and wherein the lower portion comprises the at least one containment barrier, and wherein the method comprises introducing the molten metal such that the molten metal flows through the upper portion.

18. The method of claim 14, wherein the at least one containment barrier comprises a plurality of containment barriers, and wherein the method comprises providing the plurality of containment barriers in at least two orientations relative to a direction of molten metal flow.

19. The method of claim 14, further comprising orienting the at least one containment barrier such that a first surface of the at least one containment barrier faces into a flow of the molten metal and a second surface of the at least one containment barrier faces awayfrom the flow of the molten metal, and wherein a profile of the first surface is different from a profile of the second surface.

20. The method of claim 19, wherein the first surface is planar and extends at an oblique angle relative to a bottom surface of the deep bed filter and wherein the second surface comprises a non-linear curvature.

Images